Version | 1.2 |
Unit Name | Introduction to Programmable Logic Controllers |
Unit Code | BIA205 |
Unit Duration | 1 Semester |
Award |
Bachelor of Science (Engineering) Duration 3 years |
Year Level | Two or Three |
Unit Creator / Reviewer | Dr. Pejman Peidaee |
Common/Stream: | Stream |
Pre/Co-requisites | BSC101, BSC102 |
Credit Points |
3 Total Course Credit Points 81 (27 x 3) |
Mode of Delivery | Online or on-campus. |
Unit Workload | (Total student workload including “contact hours” = 10 hours per week; 5 hours per week for 24 week delivery) Pre-recordings / Lecture – 1.5 hours Tutorial – 1.5 hours Guided labs / Group work / Assessments – 2 hours Personal Study recommended – 5 hours |
Unit Description and General Aims
The objective of this unit is to impart to the students: the ability to interpret electrical control schemes and their digital equivalent schemes; and, to design such schemes to achieve a given set of control objectives. Students will also be given sufficient instruction for them to have a thorough knowledge of the internals of a PLC, and the ability to create simple programs to achieve a given set of requirements. Students will complete a project covering the design of a control scheme, program the same on a PLC (simulation), and test the operation of this program.
Learning Outcomes
- Discuss the evolutions in industrial control system and manufacturing processes.
Bloom's Level 2 - Create logic diagrams to achieve specific control functionalities.
Bloom's Level 6 - Translate the logic diagram to create hardwired control schemes (ladder type).
Bloom's Level 4 - Design control systems of feedback/feed-forward type of control and evaluate their stability.
Bloom's Level 6 - Explain the fundamental principles behind programmable logic controllers (PLC).
Bloom's Level 4 - Distinguish between different methods of programming PLCs based on IEC 61131-3.
Bloom's Level 4 - Create and test a PLC program to achieve specific control functionalities.
Bloom's Level 6
Student assessment
Assessment Type | When assessed | Weighting (% of total unit marks) | Learning Outcomes Assessed |
Assessment 1 Type: Weekly Quizzes Description: Students will need to complete multiple-choice quiz questions to demonstrate a good understanding of the fundamental concepts. |
Ongoing | 10% | All |
Assessment 2 Type: Test (Invigilated) Example Topic: PLCs Vs Hardwired control schemes. Students will need to answer short questions and provide solutions to simple problems on the listed topics. |
Due after Topic 9 | 20% | 4, 5 |
Assessment 3 Type: Practical (Report) Example Topic: Students will complete a project covering the design of a control scheme, program the same on a PLC (simulation), and test the operation of this program. The project should include PLC program using C language and other languages having IEC 61131-3 compliance. |
Due after Topic 11 | 25% | 5, 6, 7 |
Assessment 4 Type: Exam (Invigilated) An examination with a mix of detailed report type questions and/or simple numerical problems to be completed within a given time. |
Final Week | 40% | All |
Attendance / Tutorial Participation Example: Presentation, discussion, group work, exercises, self-assessment/reflection, case study analysis, application. |
Continuous | 5% | - |
Overall requirements: Students must achieve a result of 50% or above in the exam itself to pass the exam and must pass the exam to be able to pass the unit. An overall final unit score of 50% or above must be achieved to pass the unit once all assessment, including the exam, has been completed.
Prescribed and Recommended Readings
Textbooks
- IDC Technologies Course manual on PLC programming
- IDC Technologies course manual on Control loop tuning
Notes and Reference Texts
- Raghunath Ram, 2020, An Industrial Automation: Industrial PLC Programming & Network System Basics (Series Book 1), available: https://www.goodreads.com/book/show/40679937-an-industrial-automation
- Phipps, CA, 1999, Fundamentals of Electrical Control, 2nd Edition, Fairmont Press, ISBN 978-0130126993
- Majid Pakdel, 2020, Advanced PLC Programming, 1st edition, ISBN: 9781925823790, available: https://www.booktopia.com.au/advanced-plc-programming-majid-pakdel/book/9781925823790.html
- IDC Technologies, Practical Programmable Logic Controllers (PLCs) for Automation and Process Control, IDC Technologies, Perth.
- Hackworth JR, Hackworth FD, Programmable Logic Controllers: Programming Methods and Applications. Online version available at: http://www.nfiautomation.org/FREE_Download/Technical%20Documents/PLC/%28eBook%29%20%20PLC%20Programming%20Methods.pdf
- References from authentic websites on the Internet:
For example:
http://www.plcdev.com/a_quick_tutorial_on_rslogix_emulator_5000: A Quick Tutorial on RSLogix Emulator 5000
Unit Content
Topic 1
Overview of Industrial Control System (ICS) & Applications
- Evolution of ICS
- ICS operation and Components
- ICS in Manufacturing Industries
- ICS and Interdependencies in Critical Infrastructure
Topics 2, 3 and 4
Control scheme interpretation and design
- Need for control schemes
- Symbols used in control circuits
- Motor controls – unidirectional
- Motor control – reversing
- Interlocks for control/safety
- Interpreting the operation of a control circuit
- Design a control circuit in the form of a logic diagram for a given set of requirements and evaluation using Boolean algebra principles
- Translating a logic diagram into a control circuit
- Control systems (Open and closed loop), transfer function and block diagrams
- Feedback controls and feed forward controls
- Implementation of Proportional, integral and derivative (PID) controller
- Analog and digital control
- System stability criteria and loop tuning
Topics 5 and 6
Digital logic circuits and integrated circuits for logic applications
- Fundamentals of digital electronics
- Introduction to Logic gates
- Diode-resistor logic (DRL)
- Emitter coupled logic (ECL)
- Resistor-transistor logic (RTL)
- Diode transistor logic (DTL)
- Transistor to transistor logic (TTL)
- Positive and negative logic
- Typical circuits for logic functions
- Logic gates using integrated circuits
- Other useful functions such as timers, counters, flip-flop (two-state) devices and etc. using ICs
- Introduction to clocked (dynamic) digital logic circuits
Topics 7 and 8
Programmable logic controller basics
- Historical overview
- Clocked logic as the basis of programmable logic controllers
- Fundamentals of PLC hardware
- Block diagram of a PLC
- PLC processor module
- Internal memory and its organization
- Input-output section
- Power supplies
- Noise control from I/O connections
- Recommended precautions in wiring
- Operation of dynamic logic by step-by-step execution
- Comparison of hard-wired logics with PLCs
- Possible concerns in using PLC (focus on safety systems)
Topics 9 and 10
Programming methods based on IEC standard 61131-3
- PLC programming basics
- The need for a programming standard
- Ladder logic programming
- Structured text method
- Function block method
- Instruction list
- Sequential function chart
- Comparison between IEC61131-3 and C programming
- Good programming habits
- Code organization and documentation
- Maintenance of program code and change documentation
- Simple examples of programming
- Communication between PLCs
Topic 11
Program creation and testing
- Demonstration of program writing using RSLogix 5000 emulator (or any other simulator)
- Use of chassis monitor
- Step-by-step development
- Demonstration of the program using the simulator
- Testing/troubleshooting
Topic 12
Future/ Emerging Trends
- Introduction to distributed programming and IEC 61499
- Function Blocks (FB) & Programming Organizational Units (POU)
- Functional Interfaces and FB Networks
- IEC61499-Engineering Methodologies and Design Patterns
- Modelling Intelligent Distributed Automation Systems
Software/Hardware Used
Software
- Software: Codesys & RSLogix 5000
- Version: 3.5.18.20 & 20.05
- Instructions: N/A
- Additional resources or files: N/A
Hardware
- N/A